Tutorial to making round PVC ports

[bonesninja]

Ever since i did the Got Bass? box, people have been PM'in me on how to do the ports. So here's a tutorial on how to make them.

Its sort of generic but you get the idea.

First off, i used just 2 small pieces of wood for the tutorial sake. The piece that we don't cut all the way through at first would actually represent the baffle that you want the port to exit.

So first step is to measure out where you want the ports to exit, double up the wood and drill an 1/8" hole through both pieces at once. This is very important if you want the two pieces of wood to line up just right.

http://i198.photobucket.com/albums/aa108/bonesninja/DSC02840.jpg


next, measure the OD of the PVC ....3" PVC in this case so its 3.5" OD.

http://i198.photobucket.com/albums/aa108/bonesninja/DSC02841.jpg


Next, i use my Jasper Jig and a 1/4" spiral up cut bit to route a groove 1/4" deep, set the jig to 3.5"....this will end up as your baffle that the port exits through.

http://i198.photobucket.com/albums/aa108/bonesninja/DSC02844.jpg

http://i198.photobucket.com/albums/aa108/bonesninja/DSC02845.jpg

This piece will be the brace inside the box. Use the spiral upcut and the same 3.5" hole and cut a hole all the way through

http://i198.photobucket.com/albums/aa108/bonesninja/DSC02846.jpg


you will now have two pieces like so

http://i198.photobucket.com/albums/aa108/bonesninja/DSC02847.jpg

now using Gorilla Glue, put some in the groove

http://i198.photobucket.com/albums/aa108/bonesninja/DSC02848.jpg


Now add some more Gorilla glue around the diameter of the PVC and slide the second piece over it, screw the piece on and apply some pressure to the port until the glue sets.


http://i198.photobucket.com/albums/aa108/bonesninja/DSC02849.jpg


then once the glue sets, drill a hole through the baffle, use a flush trim bit to route inside the pvc then a roundover to eliminate the sharp edges

[DB-Audio]

cool dude I've been wanting to do that on my next box build

[bonesninja]

cool dude I've been wanting to do that on my next box build

its very simple and make sure you let the glue dry before removing the pressure.....and i do this on both ends of the port so the end has good support

[DonH]

REALLY SMART WAY! i am trully amazed! haha never would have thought of this! gona try this today!

[Millertime1028]

This is exactly how I incorporated my sono tubes into my current box. Although it was a bit more tedious as the sono tubes were not exactly round. With PVC its nice. Like to see it as a write up. Did you use a flush bit on the inside port walls and the outer baffle. I did this then used bondo, then sanded to give it a seamless look with the inner port wall and outer baffle. Worked nicely and was fairly easy IMO .

[bonesninja]

This is exactly how I incorporated my sono tubes into my current box. Although it was a bit more tedious as the sono tubes were not exactly round. With PVC its nice. Like to see it as a write up. Did you use a flush bit on the inside port walls and the outer baffle. I did this then used bondo, then sanded to give it a seamless look with the inner port wall and outer baffle. Worked nicely and was fairly easy IMO .

yes

[rollerdj]

got any pic's of the finished product? i never saw the build.

[jmanpc]

I just cut a hole in the MDF to match the OD of the PVC, and then coat the inside of the cutout and the outside of the PVC with gorilla glue. Then I set it down on a piece of newspaper and let it cure. When it's dry, sand off the newspaper and hit it with a roundover bit.

Ending result:

http://i2.photobucket.com/albums/y13/goatboy_521/IMG_0299.jpg

http://i2.photobucket.com/albums/y13/goatboy_521/IMG_0300.jpg

It might take a little filler to make it smooth, too.

[bonesninja]

got any pic's of the finished product? i never saw the build.

http://i198.photobucket.com/albums/aa108/bonesninja/IMG00237.jpg

[bonesninja]

http://www.caraudio.com/forum/showthread.php?t=393160

[iamamp3pimp]

im going to do one of these when i rebuild the enclosure for my HT sub.

[cf2004]

thanks for taking the time to make a tutorial on this. great info to have!

[72 chevy van]

I do all my round ports like that.

[302yota]

did you flare the inner part of the port....you may have i just kinda got lost when you said something about slide the second piece on, screw and apply pressure.. or something like that.

[microhaxo]

Sweet, just what i needed! Thanks..

[jmanpc]

Nice lookin ports!

[I Like Waffle]

thats alot of work on those ports man :eek:



My first round port job - done with a jigsaw, mdf, and liquid nails. Turned out **** though i think. I rounded the inside of the ports out some and sunk them into the box about 1/4 inch. Theyre supported at the back with MDF to keep them level, and liquid nails around the inside. Next time i do it though it will be much cleaner and easier since i did it the hard way this time. I need a router :crap:


http://i43.tinypic.com/2j4vfq0.jpg

http://i41.tinypic.com/10dimpe.jpg


First try win?

[bonesninja]

thats alot of work on those ports man :eek:


its not bad at all once you get the idea

[fshanda]

From when I changed my port from a 3" to a 4" port.

I add a coupling to the ends and use a sink roundover bit on the ends to flare the openings. I also cut the OD of the pipe and epoxy it to the enclosure and finish.

http://farm1.static.flickr.com/183/432400261_4d6cb272cc_o.jpg

http://farm1.static.flickr.com/133/413973478_8348581832_o.jpg

http://farm1.static.flickr.com/129/413973481_b166605442_o.jpg

http://farm1.static.flickr.com/236/448842777_a6f51e45af_o.jpg

http://farm1.static.flickr.com/179/448842759_82c67ea7e4_o.jpg

[gotparts90]

set it deeper and use 1.5 inch round over and it makes almost no port noise on 4 inch. that technique is from the Yamaha enclosure book IIRC. yours is a little different but about the same.